Permanent tooling for composite coil spring compression molding

ABSTRACT

An inner mandrel for forming a variable taper component includes a master insert and a plurality of interlocking pieces. The master insert includes opposed tapered edge faces, each tapered edge face defining at least one locking feature, a first surface having a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface. Each interlocking piece includes opposed tapered edge faces, one of the opposed tapered edge faces defining a locking feature and another of the opposed tapered edge faces defining a receiving feature to engage the locking feature of an adjacent interlocking piece, a first surface defining a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of and claims the benefit of U.S.application Ser. No. 16/682,846, filed Nov. 13, 2019, now U.S. Pat. No.11,318,660, and titled “PERMANENT TOOLING FOR COMPOSITE COIL SPRINGCOMPRESSION”, the content of which is incorporated herein by referencein its entirety.

FIELD

The present disclosure relates to tooling, and more specifically totooling for forming variable taper components such as coil springs.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Most commercially available tooling for variable taper components, suchas composite coil springs, are destroyed after forming the variabletaper component in order to remove the variable taper component from thetrapped tooling. For example, and referring to FIG. 1 , a variable tapercomposite coil spring 10 is shown, which includes a smaller diameterportion 12 at each end and a larger diameter portion 14 in the center.An inner mandrel (not shown) used to form this variable taper compositecoil spring 10 is then “locked” inside after the variable tapercomposite coil spring 10 is formed/cured. Accordingly, the inner mandrelmust be destroyed in order to remove the variable taper composite coilspring 10 from the inner mandrel. The inner mandrel is thenremanufactured to produce each additional spring, which is costly andtime consuming.

Other commercially available tooling uses a bismuth core mandrel that ismelted out of the variable taper component after forming and then recastafter each variable taper component is produced. This process greatlyincreases the part cost for each variable taper component.

The present disclosure addresses these issues with variable tapercomponents, among other issues related to tooling for variable tapercomponents, such as composite coil springs.

SUMMARY

In one form of the present disclosure, tooling for use in forming avariable taper component is provided. The tooling comprises an innermandrel comprising a master insert defining opposed tapered edge faces,each opposed tapered edge face defining at least one locking feature, anexternal surface having a variable taper and a plurality of recessesconfigured to receive at least a portion of the variable tapercomponent, and a tapered internal surface. The inner mandrel furthercomprises a plurality of interlocking pieces arranged concentricallyaround the master insert, each interlocking piece defining opposedtapered edge faces, one of the opposed tapered edge faces defining atleast one locking feature and another of the opposed tapered edge facesdefining at least one receiving feature to engage the at least onelocking feature of an adjacent interlocking piece, an external surfacedefining a variable taper and a plurality of recesses configured toreceive at least a portion of the variable taper component, and atapered internal surface. Additionally, the inner mandrel comprises atapered inner sleeve disposed against the tapered internal surfaces ofthe plurality of interlocking pieces and the master insert. The toolingfurther comprises an outer mandrel disposed around the inner mandrel,the outer mandrel defining a corresponding plurality of recessesconfigured to receive at least a portion of the variable tapercomponent, wherein a maximum width of each of the interlocking piecesand the master insert is smaller than a minimum width of end portions ofthe variable taper component, and a central portion of the variabletaper component is wider than the end portions.

In variations of this tooling, the opposed tapered edge faces of themaster insert and the plurality of interlocking pieces are normal to anexternal surface of the central portion of the variable taper component,the locking feature is a linear tab and the receiving feature is alinear slot, the locking feature is a T-shaped tab and the receivingfeature is a T-shaped slot, the locking feature and the receivingfeature are magnetic, the variable taper is continuously variable alongend portions of the tooling and is constant along a central portion ofthe tooling, the plurality of recesses in the master insert, theplurality of interlocking pieces, and the outer mandrel define avariable taper helix, the number of the plurality of interlocking piecesis four (4), the outer mandrel defines at least two (2) pieces, thetapered inner sleeve further comprises a removal feature, the at leastone locking feature of the master insert and the plurality ofinterlocking features define a pitch that is equal to a pitch of thevariable taper component.

In another variation of this tooling, a top member is disposed above themaster insert and the plurality of interlocking pieces, the top memberdefining a locking feature and at least one of the plurality ofinterlocking pieces further defining a receiving feature disposed at anupper portion that engages the receiving feature of the top member.

In another form of the present disclosure, an inner mandrel for formingvariable taper component is provided. The inner mandrel comprises amaster insert defining opposed tapered edge faces, each tapered edgeface defining at least one locking feature, an external surface having avariable taper and a plurality of recesses configured to receive atleast a portion of the variable taper component, and a tapered internalsurface. The inner mandrel further comprises a plurality of interlockingpieces arranged concentrically around the master insert, eachinterlocking piece defining opposed tapered edge faces, one of theopposed tapered edge faces defining at least one locking feature andanother of the opposed tapered edge faces defining at least onereceiving feature to engage the at least one locking feature of anadjacent interlocking piece, an external surface defining a variabletaper and a plurality of recesses configured to receive at least aportion of the variable taper component, and a tapered internal surface.Additionally the inner mandrel comprises a tapered inner sleeve disposedagainst the tapered internal surfaces of the plurality of interlockingpieces and the master insert, wherein a maximum width of each of theinterlocking pieces and the master insert is smaller than a minimumwidth of an end portion of the variable taper component, and a centralportion of the variable taper component is wider than the end portions.

In a variation of this inner mandrel, a top member is disposed above themaster insert and the plurality of interlocking pieces, the top memberdefining a locking feature and at least one of the plurality ofinterlocking pieces further defining a receiving feature disposed at anupper portion that engages the receiving feature of the top member.

In another variation of this inner mandrel, the tapered inner sleevefurther comprises a removal feature.

In yet another form of the present disclosure, a method of forming avariable taper component is provided. The method comprises placing avariable taper component preform around the inner mandrels as describedherein and forming a variable taper component from the variable tapercomponent preform.

In a variation of this method, prior to the forming step, an outermandrel is placed around the variable taper component preform and theinner mandrel, the outer mandrel defining a corresponding plurality ofrecesses configured to receive at least a portion of the variable tapercomponent preform. This variation may further comprise injecting amaterial into the recesses of the inner mandrel and the outer mandrel,wherein the forming step comprises injection molding.

In another form of this method, the forming step comprises compressionmolding. Additionally, a composite coil spring, among other variabletaper components, is formed according to the methods of the presentdisclosure.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which:

FIG. 1 is a perspective view of a variable taper composite coil springaccording to the prior art;

FIG. 2 is a perspective view of tooling for forming a variable tapercomponent constructed according to the teachings of the presentdisclosure;

FIG. 3 is a perspective view of an inner mandrel and a variable tapercomponent constructed according to the teachings of the presentdisclosure;

FIG. 4A is an exploded view of FIG. 3 ;

FIG. 4B is a perspective view of an alternate form of the tapered innersleeve constructed in accordance with the teachings of the presentdisclosure;

FIG. 4C is a perspective view of the underside of an alternate topmember constructed in accordance with the teachings of the presentdisclosure;

FIG. 4D is a perspective view of the top member of FIG. 4C engaging aninterlocking piece and constructed in accordance with the teachings ofthe present disclosure;

FIG. 4E is a perspective view of the top member of FIG. 4C engagingthree (3) interlocking pieces and constructed in accordance with theteachings of the present disclosure;

FIG. 5A is a side view illustrating an external portion of a masterinsert of tooling constructed in accordance with the teachings of thepresent disclosure;

FIG. 5B is a side view illustrating an internal portion of the masterinsert of FIG. 5A;

FIG. 5C is a rotated side view of the master insert of FIG. 5A;

FIG. 5D is another rotated side view of the master insert of FIG. 5A;

FIG. 5E is the same view as FIG. 5D, illustrating a variable taper of anexternal surface of the master insert of FIG. 5A;

FIG. 5F is a top view of the master insert of FIG. 5A;

FIG. 5G is a perspective top view of the master insert of FIG. 5A;

FIG. 6A is a rotated side view of an interlocking piece constructed inaccordance with the teachings of the present disclosure;

FIG. 6B is another rotated side view of the interlocking piece of FIG.6A;

FIG. 6C is another rotated side view of the interlocking piece of FIG.6A;

FIG. 6D is a side view of the interlocking piece of FIG. 6A;

FIG. 6E is a top view of the interlocking piece of FIG. 6A;

FIG. 6F is a top perspective view of the interlocking piece of FIG. 6A;

FIGS. 7A through 7L illustrate a sequence of disassembling and removingan inner mandrel from a variable taper component according to theteachings of the present disclosure;

FIG. 8 is a perspective view of a portion of an outer mandrelconstructed according to the teachings of the present disclosure; and

FIG. 9 illustrates alternative locking features of the master insertand/or interlocking pieces constructed according to the teachings of thepresent disclosure.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

Referring to FIGS. 2 through 4 , tooling 20 for use in forming avariable taper component 30 is shown. The tooling 20 generally comprisesan inner mandrel 40 comprised of several pieces, which are described ingreater detail below, and in some forms includes an outer mandrel 120.

The inner mandrel 40 comprises a master insert 60, a plurality ofinterlocking pieces 80, and a tapered inner sleeve 100. As shown, theplurality of interlocking pieces 80 are arranged concentrically aroundthe master insert 60, and each of the components of the inner mandrel 40are designed to be assembled and disassembled in a specific order sothat they may be reused for each subsequent forming operation to producethe variable taper component 30, which is described in greater detailbelow.

Referring first to FIGS. 5A-5G, the master insert 60 is illustrated ingreater detail. The master insert 60 defines opposed tapered edge faces62, an external surface 66, and a tapered internal surface 72. Eachopposed tapered edge face 62 defines at least one locking feature 64,which is configured to engage a corresponding receiving feature in theadjacent interlocking pieces, which is illustrated and described ingreater detail below. Although a total of four (4) locking features 64are shown, two (2) on each opposed tapered edge face 62, it should beunderstood that any number of locking features may be employed, and in anumber of locations besides those illustrated, while remaining withinthe scope of the present disclosure.

The external surface 66 includes a variable taper 68 (represented by anoffset phantom profile in FIG. 5E) as shown and a plurality of recesses70 configured to receive at least a portion of the variable tapercomponent 30. The variable taper 68 is relative to a longitudinal axis Xof the inner mandrel 40 and should be construed to mean that thegeometry, or profile, of the external surface 66 increases and decreasesalong the longitudinal axis X. Further, it should be understood that thevariable taper need not be symmetrical about a central portion of theinner mandrel 40 as shown herein and may further be continuouslyvariable or have zones having the same taper transitioning to zoneshaving a different taper while remaining within the scope of the presentdisclosure. In one form, the taper is continuously variable from thecenter portion to the end portions while remaining constant along acentral portion of the tooling 20.

Generally, the variable taper 68 of the external surface 66 correspondsto the geometry of the variable taper component 30 being formed from thetooling 20, which has smaller end portions and a larger center portionas previously described.

Referring now to FIG. 4A and FIGS. 6A-6F, one of the interlocking pieces80 is shown in greater detail. Each interlocking piece 80 definesopposed tapered edge faces 82, an external surface 88, and a taperedinternal surface 94. One of the opposed tapered edge faces 82 of eachinterlocking piece 80 defines at least one locking feature 84, andanother of the opposed tapered edge faces 82 defines at least onereceiving feature 86 to engage the at least one locking feature 84 of anadjacent interlocking piece 80. Similar to the master insert 60 asdescribed above, although a total of two (2) locking features 84 areshown with two (2) corresponding receiving features 86 on eachinterlocking piece 80, it should be understood that any number oflocking features and receiving features may be employed, and in a numberof locations besides those illustrated, while remaining within the scopeof the present disclosure.

The external surface 88 defines a variable taper 90 (represented by anoffset phantom profile in FIG. 6B) and a plurality of recesses 92configured to receive at least a portion of the variable taper component30. Notably, due to the plurality of recesses 92 configured to receivethe variable taper component 30 and the tapered internal surface 94,each interlocking piece 80 of inner mandrel 40 is unique.

Generally, each of the opposed tapered edge faces 62 of master insert 60and the opposed tapered edge faces 82 of the interlocking pieces 80 arenormal to an external surface of a central portion 34 of the variabletaper component 30 for ease of removal, which is illustrated anddescribed in greater detail below. Further, a maximum width of each ofthe interlocking pieces 80 and the master insert 60 is smaller than aminimum width of end portions 32 of the variable taper component 30,also for ease of removal. Additionally, at least one locking feature 64of the master insert 60 and at least one locking feature 84 of theplurality of interlocking features 80 define a pitch that is equal to apitch of the variable taper component. In other words, the lockingfeatures 64/84 are at angle relative to each other across the masterinsert 60 and the interlocking pieces 80 that matches the angle of thevariable taper component, in one form of the present disclosure.

Now referring back to FIG. 4A, the tapered inner sleeve 100 in one formis hollow and generally defines a portion of a geometrical cone.However, it should be understood that the tapered inner sleeve 100 couldbe hollow or solid, and could further include a removal feature asdescribed in greater detail below. The external surface of the taperedinner sleeve 100 is generally configured to mate to the tapered internalsurfaces 72 and 94 of the master insert 60 and interlocking pieces 80,respectively. Further, the tapered inner sleeve has a wider proximal endportion 102 and a narrower distal end portion 104, thus forming thetaper.

Referring to FIG. 4B, in an alternate form, the tapered inner sleeve100′ includes a removal feature 101, which is configured to assist inremoving or inserting the tapered inner sleeve 100 within the assembledmaster insert 60 and plurality of interlocking pieces 80. In this form,the removal feature 101 is a handle that extends across and interiorportion of the tapered inner sleeve 100, which can be grasped by anoperator or a machine/robot. It should be understood that thisparticular handle configuration is merely exemplary, and a wide varietyof removal features may be employed while remaining within the scope ofthe present disclosure.

Referring now to FIGS. 4C-4E, in another alternate form, a top member130 is disposed above the master insert 60 (not shown) and the pluralityof interlocking pieces 80, the top member 130 defining a locking feature132 and at least one of the plurality of interlocking pieces 80 furtherdefining a receiving feature 134 disposed at an upper portion thatengages the locking feature 132 of the top member 130. (Only one (1)interlocking piece 80 is shown in FIG. 4D and only three (3)interlocking pieces are shown in FIG. 4E for purposes of clarity). Thelocking feature 132 in this form defines a center rail 136 on a platform138, and a rear wall 140. With this configuration of a locking feature132, the center rail 136 provides circumferential positioning, theplatform 138 provides axial positioning, and the rear wall 140 providesradial positioning for the respective interlocking piece 80. With thisalternate top member 130, the individual pieces/components of the innermandrel 40 can be more securely locked together.

It should be understood that the specific locking feature 132illustrated and described herein is merely exemplary, and thus otherlocking features may be employed while remaining within the scope of thepresent disclosure. Also, it should be understood that the lockingfeatures and receiving features illustrated and described throughout maybe interchanged and placed on either of the adjacent components beinglocked together.

As further shown in FIGS. 4D and 4E, an alternate marking indicia 142may be provided on components of the inner mandrel 40. For example, anumbering system can be used on each of the master insert 60 and theinterlocking pieces 80 (shown with the numerals “3” and “4” and “5”) toassist an operator or machine vision system as to which pieces should beassembled and disassembled in which particular order.

Generally, to assemble the inner mandrel 40, each of the interlockingpieces 80 are engaged with each other first, and the master insert 60 isthen slid into place via the locking features 84 and receiving features86. The tapered inner sleeve 100 is then slid into the center of theinner mandrel 40, and by virtue of its taper, forces each of theinterlocking pieces 80 and the inner mandrel 40 together in aninterlocking fashion.

Referring now to FIGS. 4 and 7A through 7L, the inner mandrel 40 isconfigured to be disassembled and reused after forming a variable tapercomponent 30. In FIG. 7A, the variable taper component 30 has beenformed around the inner mandrel 40. After the variable taper component30 is formed, as shown in FIG. 7B, the tapered inner sleeve 100 istranslated (along the longitudinal axis X) or pulled out of the centerof the inner mandrel 40. Since the tapered inner sleeve 100 pressesagainst tapered internal surfaces 72 and 94, the removal of taperedinner sleeve 100 allows the master insert 60 to move. Accordingly, inFIG. 7C, the master insert 60 is moved inwardly, away from the variabletaper component 30 and towards the center of the inner mandrel 40, andthe locking features 64 slidably decouple from receiving features 86 ofthe adjacent interlocking pieces. As shown in FIG. 7D, master insert 60can then be removed, or pulled out from the center of the inner mandrel40.

Because the master insert 60 couples to opposed tapered edge faces 82and receiving features 86 of adjacent interlocking pieces 80, theremoval of the master insert 60 then allows at least one interlockingpiece 80 to move. As shown in FIG. 7E, locking features 84 of oneinterlocking piece can be slidably decoupled from receiving features 86of an adjacent interlocking piece 80, and the interlocking piece 80 canthen be moved inwardly, away from the variable taper component 30 andtowards the center of the inner mandrel 40, for its removal as shown inFIG. 7F.

This procedure for removing an interlocking piece 80 is then repeated asshown in FIGS. 7G through 7L, so that the remaining interlocking pieces80 can be removed, thus freeing the variable taper component 30 from theinner mandrel 40. Advantageously, the inner mandrel 40 can be removedand reused in forming another variable taper component 30 without beingdestroyed.

Referring to FIG. 8 , a side view of one half of the outer mandrel 120from is shown. The outer mandrel 120 comprises a face 122 and aninternal surface 124. The internal surface 124 defines a correspondingplurality of recesses 126 configured to receive at least a portion ofvariable taper component 30. Generally, the internal surface 124 isconfigured to couple, or conform to the variable taper component 30 andthe external geometries of the master insert 60 and interlocking pieces80. Accordingly, the tooling 20 can be used in a variety ofmanufacturing operations such as, by way of example, compression moldingor injection molding. Although a two-piece outer mandrel 120 is shownherein, it should be understood that any number of pieces, oralternatively a conformal bladder or other tooling design, may beemployed for the outer mandrel while remaining within the scope of thepresent disclosure.

In a compression molding application, the inner mandrel 40 is firstassembled, and then a variable taper component preform (not shown) isplaced within the recesses 70 and 92 of the master insert 60 and theinterlocking pieces 80, respectively. The outer mandrel 120 is thenplaced around the variable taper component preform and the inner mandrel40, and this assembly is placed in a compression molding die/tool. Afterforming, the outer mandrel 120 is removed first, and then the innermandrel 40 is disassembled as described above. The variable tapercomponent 30 can then be removed for further processing withoutdestroying any tooling.

Similarly, for injection molding, the inner mandrel 40 and the outermandrel 120 are assembled together (and positioned relative to eachother with tooling features not shown), and then this assembly is placedinto an injection molding tool. Molten resin, or molten resin withembedded fibers, can then be injected into the recesses 70 and 92 of themaster insert 60 and the interlocking pieces 80, respectively, and therecesses 126 of the outer mandrel 120, to form the variable tapercomponent 30. The outer mandrel 120 and inner mandrel 40 are removed asset forth above.

It should be understood that compression molding and injection moldingare merely two examples of forming a variable taper component, and otherprocesses are to be considered within the scope of the presentdisclosure. Further, a variety of part types may be formed using theinnovative tooling 20 according to the teachings of the presentdisclosure. For example, a composite coil spring can be formed accordingto the teachings herein. The composite coil spring may comprisecontinuous or discontinuous fibers, which may be glass or carbon by wayof example, in a curable resin matrix. The curable resin matrix can beeither thermoset or thermoplastic.

Further, as illustrated herein, the plurality of recesses 70/92/126 inthe master insert 60, the plurality of interlocking pieces 80, and theouter mandrel 120, respectively, define a variable taper helix in oneform of the present disclosure.

The master insert 60, interlocking pieces 80, tapered inner sleeve 100,outer mandrel 120 and components thereof (e.g. locking feature,receiving feature, among others) can be made of any material that canwithstand the processing temperatures and pressures when forming thevariable taper component 30. As such, a tool steel is contemplated inone form, although other materials such as ceramics (e.g. alumina,carbides graphite, magnetic, nitrides, non-oxide, oxide, sand, silica,zirconia, among others), composites, other metals (e.g. aluminum-based,iron-based, magnetic, nickel-based, titanium-based, among others),polymers and combinations of these materials may comprise the masterinsert, interlocking pieces, tapered inner sleeve, and outer mandrel.Moreover, different materials can be used for each of the master insert60, interlocking pieces 80, tapered inner sleeve 100, and outer mandrel120 while remaining within the scope of the present disclosure.

Referring now to FIG. 9 , alternative forms of locking features 64 of amaster insert 60 are shown. It should be understood that these lockingfeatures 64, and combinations thereof, may also be used with the lockingfeatures 84 of the interlocking pieces 80 while remaining within thescope of the present disclosure. In the first form, the locking feature64 is a linear tab, while the receiving feature 86 (shown in FIG. 4A) isa linear slot. In an alternate form, the locking feature 64′ is aT-shaped tab, while the receiving feature (not shown) is a T-shapedslot. In yet another form, the locking features may be magnetic, whetherphysical interlocking or exclusively magnetically interlocking. Itshould be understood that these exemplary variations, among others, maybe employed to interlock the components of the inner mandrel 40 whileremaining within the scope of the present disclosure.

Unless otherwise expressly indicated herein, all numerical valuesindicating mechanical/thermal properties, compositional percentages,dimensions and/or tolerances, or other characteristics are to beunderstood as modified by the word “about” or “approximately” indescribing the scope of the present disclosure. This modification isdesired for various reasons including industrial practice; material,manufacturing, and assembly tolerances; and testing capability.

As used herein, the phrase at least one of A, B, and C should beconstrued to mean a logical (A OR B OR C), using a non-exclusive logicalOR, and should not be construed to mean “at least one of A, at least oneof B, and at least one of C.”

The description of the disclosure is merely exemplary in nature and,thus, variations that do not depart from the substance of the disclosureare intended to be within the scope of the disclosure. Such variationsare not to be regarded as a departure from the spirit and scope of thedisclosure.

What is claimed is:
 1. Tooling for use in forming a variable tapercomponent, the tooling comprising: an inner mandrel comprising: a masterinsert defining: opposed first tapered edge faces, each first taperededge face defining a first locking feature; a first surface defining afirst variable taper and a plurality of first recesses configured toreceive a first interior portion of the variable taper component; and atapered second surface opposite the first surface; a plurality ofinterlocking pieces arranged with the master insert about an axis of theinner mandrel, each interlocking piece defining: opposed second taperededge faces, one of the opposed second tapered edge faces defining asecond locking feature and another of the opposed second tapered edgefaces defining a first receiving feature to engage the second lockingfeature of an adjacent interlocking piece; a third surface defining asecond variable taper and a plurality of second recesses configured toreceive a different interior portion of the variable taper component;and a tapered fourth surface opposite the third surface; a memberconfigured to engage the interlocking pieces to secure the interlockingpieces together; and an outer mandrel disposed around the inner mandrel,the outer mandrel defining a corresponding plurality of third recessesconfigured to receive an exterior portion of the variable tapercomponent, wherein a maximum width of each of the interlocking piecesand the master insert is smaller than a minimum width of end portions ofthe variable taper component, and a central portion of the variabletaper component is wider than the end portions.
 2. The tooling accordingto claim 1, wherein the opposed first tapered edge faces of the masterinsert and the plurality of interlocking pieces are normal to a surfaceof the central portion of the variable taper component.
 3. The toolingaccording to claim 1, wherein at least one of the first locking featureand the second locking feature is a linear tab and the first receivingfeature is a linear slot.
 4. The tooling according to claim 1, whereinat least one of the first locking feature and the second locking featureis a T-shaped tab and the second receiving feature is a T-shaped slot.5. The tooling according to claim 1, wherein at least one of the firstlocking feature and the second locking feature is magnetic and the firstreceiving feature is magnetic.
 6. The tooling according to claim 1,wherein the first and second variable tapers are continuously variablealong end portions of the tooling and are constant along a centralportion of the tooling.
 7. The tooling according to claim 1, wherein theplurality of first recesses, the plurality of second recesses, and theplurality of third recesses cooperate to define a variable taper helix.8. The tooling according to claim 1, wherein a number of the pluralityof interlocking pieces is four (4).
 9. The tooling according to claim 1,wherein the outer mandrel defines at least two (2) pieces.
 10. Thetooling according to claim 1, wherein the member comprises a top memberdisposed above the master insert and the plurality of interlockingpieces, the top member defining a third locking feature and at least oneof the plurality of interlocking pieces further defining a secondreceiving feature disposed at an upper portion that engages the thirdlocking feature of the top member.
 11. The tooling according to claim 1,wherein the member comprises an inner sleeve secured to the fourthsurfaces of the plurality of interlocking pieces and the second surfaceof the master insert.
 12. The tooling according to claim 1, wherein thefirst locking feature of the master insert and the second lockingfeatures of the plurality of interlocking pieces define a pitch that isequal to a pitch of the variable taper component.
 13. An inner mandrelfor forming a variable taper component, the inner mandrel comprising: amaster insert defining: opposed first tapered edge faces, each firsttapered edge face defining a first locking feature; a first surfacedefining a first variable taper and a plurality of first recessesconfigured to receive a first interior portion of the variable tapercomponent; and a tapered second surface opposite the first surface; aplurality of interlocking pieces arranged with the master insert aboutan axis of the inner mandrel, each interlocking piece defining: opposedsecond tapered edge faces, one of the opposed second tapered edge facesdefining a second locking feature and another of the opposed secondtapered edge faces defining a first receiving feature to engage thesecond locking feature of an adjacent interlocking piece; a thirdsurface defining a second variable taper and a plurality of secondrecesses configured to receive a different interior portion of thevariable taper component; and a tapered fourth surface opposite thethird surface; and a member configured to engage the interlocking piecesto secure the interlocking pieces together, wherein a maximum width ofeach of the interlocking pieces and the master insert is smaller than aminimum width of an end portion of the variable taper component, and acentral portion of the variable taper component is wider than the endportions.
 14. The inner mandrel according to claim 13, wherein themember comprises an inner sleeve secured to the fourth surfaces of theplurality of interlocking pieces and the second surface of the masterinsert.
 15. The inner mandrel according to claim 13, wherein the membercomprises a top member disposed above the master insert and theplurality of interlocking pieces, the top member defining a thirdlocking feature and at least one of the plurality of interlocking piecesfurther defining a second receiving feature disposed at an upper portionthat engages the third locking feature of the top member.
 16. A methodof forming a variable taper component comprising: placing a variabletaper component preform around the inner mandrel according to claim 13;and forming a variable taper component from the variable taper componentpreform.
 17. The method according to claim 16, further comprising, priorto the forming step, placing an outer mandrel around the variable tapercomponent preform and the inner mandrel, the outer mandrel defining acorresponding plurality of third recesses configured to receive anexterior portion of the variable taper component preform.
 18. The methodaccording to claim 17, further comprising injecting a material into thefirst and second recesses of the inner mandrel and the third recesses ofthe outer mandrel, wherein the forming step comprises injection molding.19. The method according to claim 16, wherein the forming step comprisescompression molding.
 20. A composite coil spring formed according to themethod of claim 16.